VALORISATION DE SOUS-PRODUITS PAR COMBINAISON DE … · VALORISATION DE SOUS-PRODUITS. PAR...

VALORISATION DE SOUS-PRODUITSPAR COMBINAISON DE PROCEDES

Florence Lutin – R&D Director

EURODIA INDUSTRIE – Pertuis –F84120 - France

Green Food Tech – Quebec – 2nd October 2018

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INTRODUCTION

Major drivers for using (ZLD = Zero Liquid Discharge) are environmental regulations for the discharge of specific solutes, toxic elements and SALTS

Conventional process to achieve ZLD : Evaporation – Crystallization High CAPEX and OPEX linked to high energy

consumption

More Energy-saving processes : Membrane technologies as Reverse osmosis (RO), Nanofiltration (NF), Electrodialysis (ED)

Summary

Introduction

Dairy Industries : whey demineralization plant

Sugar Industries : decolorization line in sugar refineries

Wine Industries : wine tartaric stabilization

Conclusions - Perspectives

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SUMMARY

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DAIRY INDUSTRIES Whey demineralization plant

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WHEY = A VALUABLE RAW MATERIAL

29,20% 26,20% 37,70% 6,90%Cow milk

(dry matter)

FatProteinsLactoseAsh (+ vitamins)

Fat for Cheese / butter / cream…

Casein for Cheese / Casein production…

Whey, co-product of milk transformation :- Whey proteins- Lactose- Minerals (+ vitamins)

Dairy Industry – Whey Demineralization

FOR WHICH INGREDIENTS WHEY IS USED ?

INFANT FORMULA

DM70 DM90

BEVERAGELactose.DM70

ICE CREAMWPC

SWEETENER

YOGHURTWPC

BACKERYDM50 up to

DM90

CANDIESDM50 up to

DM90

ANIMAL FEEDDM40


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EURODIA is combining part or all technologies to demineralize, function of physico-chemical composition

Ion exchange

Electrodialysis

Filtration Systems(NF, RO)

DEMINERALIZATION RATE (on dry matter)

PRODUCT

SWEET WHEY6% DS

SWEET WHEY18-24% DS ELECTRODIALYSIS ELECTRODIALYSIS

RESINS+

NANOFILTRATION

ELECTRODIALYSIS+

RESINS+

NANOFILTRATION

RESINS+

ELECTRODIALYSIS

NANOFILTRATION

30 % 50 - 70 % > 90 %

Production of demineralization whey


MORE THAN 370 000T OF DEMINERALIZED WHEY ARE PRODUCED ON EURODIA LINES

> 60 000 m2 membranes area

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Demineralization linesConsume water and chemicalsGenerate effluent load

These 2 points are extremely critical depending on :The country (effluent limitation-regulation / water availability)The capacity of the existing waste water treatment plantThe availability and cost of chemicals

Since 2008, EURODIA has developed a cost-effective and sustainable process solution as a complement of whey demineralization line.

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Liquid sweet whey

Ion exchange

Nanofiltration

Electrodialysis

Acid pasteurization

Ion exchange

pH adjustment

Dem90

Water / Chemical recovery process

Water recovery

EFFLUENT COLLECTION

NF permeate

ED brine

Part of regeneration

Water recovery

Effluent to waste water treatment plant (from the complete process line)


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Collected effluents Filtration unit Bipolar ED Final effluents

Process water

By-product

Acid / Base solutions

1

2

3

1 Process water : used for IEX regeneration cycle / ED brine / membrane unit CIP (ED & filtration systems)

For example on a complete D90 line :Raw whey = liquid whey (6% DS) : complete autonomy in

water (and even overproduction)

Raw whey = RO/NF whey (18-20% DS) : recovery of ~ 50% water consumption

Water recovery Chemical recovery

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2 By-product which can be valorized as animal feed (~ 25% lactose + NPN / ~ 75% ash + organic acids)

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Collected effluents Filtration unit Bipolar ED Final effluents

Process water

By-product

Acid / Base solutions

1

2

3

Water recovery Chemical recovery

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3 Acid / Base solutions : used for IEX regeneration cycle

For example on a complete D90 line :Raw whey = liquid whey (6% DS) : saving of ~35% HCl

consumption / ~60% of NaOH consumption

4 Reduction of ~ 40% of the effluent BOD released in the waste water treatment plant

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BIPOLAR ELECTRODIALYSISDairy Industry – Whey Demineralization

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Water / chemical recovery solution allows :Much lower water consumptionRecovery of valuable by-productsReduction of effluent loadReduction of chemical consumption

=> With no significant increase of the whole operating cost

⇒Perspective : 100 % water recovery 100 % chemical recovery Discharge = “natural” minerals + organics coming from

whey becoming a valuable product


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SUGAR INDUSTRIESDecolorization Line in Sugar refinery

CANE RAW SUGAR

AFFINATIONREMELT

LIMINGCARBONATATION

MAIN FILTRATIONSAFETY FILTRATION

DECOLORATION

EVAPORATIONCRYSTALLISATION

CANE REFINED SUGAR

Colour > 2000 icumsaColour < 2000 icumsa

Refining capacity: 1500 t/day

Sugar Industry – Decolorization line

The use of resins as decolorization method step found a new development when nanofiltration membranes have demonstrated their industrial efficiency by decreasing salt consumption and, as a consequence, helping the treatment of the effluents. Nanofiltrationis now considered as a standard for decoloration units.

Based on that Knowledge, Eurodia is able to adapt its decolorizationprocess to customer expectation : Limit the chloride content in the effluent sent to ponds (Italy) Limit water consumption and reduce waste water disposal as

much as possible (Middle East)


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REGENERATION CONDITIONS

Basic brine: NaCl 100 g/l + NaOH 5 - 10 g/l Regeneration level: 150 – 200 g NaCl/lres,

# 2,5 – 3,0 eq/lres Temperature : 60 – 80 °c pH : 12 -13

REGENERATION MECHANISMS

Osmotic chock Decrease hydrophobic interaction Ion exchange Cl capacity: < 0,2 eq/lresin

DECOLORATION RESINS REGENERATION

UP FLOW Décoloration

PA

FA

PB

FB

PC

FC

DOWN FLOW Regeneration


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0 10 20 30 40 50 60 70 80 90

100

0 1 2 3 4 5 6

g/l o

u un

ité D

O

BV

DO

NaCl

DCO

1- Recoverable water2- Salty colored water3- Colored Brine

1 43 5TYPICAL ELUTION PROFILE

2

4- Salty water5- Recoverable water


EURODIA PATENTED PROCESS

Strictly confidential

1. Brine2. Displacement3. Rinsing

Low salt conc

High salt conc

High salt conc

4. Molasses

DECOLO RONF ED

« No » brine consumption« No » waste discharge from resins regeneration« No » water consumption+/-10 times less energy consumption compared with

evaporator option

PERFORMANCES

OPERATIONS

Sugar Industry – Decoloration line

P

P

R

R

Strictly confidential

KEY FIGURES

NF NF + EVAPORATOR NF + RO + ED*

+ «The» Standard Low Investiment

High brine recoveryHigh quality water recovery

Low energy demandProven technology

- Low Brine Water Recovery

Energy demandConstruction material for

evaporatorCAPEX

* Patented


KEY FIGURES


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WINE INDUSTRIES Wine tartaric stabilization

WINE STABILIZATION WITH ED MARKET IS GROWING!

Over the last 18 years, ED has been extensively used for the Tartarate Stabilization for all types of wines.

By end 2017, 230 plants in operation worldwide/25 countries

Total volume of treated wine by ED : 1.2 Billion bottles/year – 40 000 m2 of membrane area installed

ED (wine stabization)-EDBM(pH adjustment) = SUBTRACTIVE Technologies : No chemical addition

ECO-FRIENDLY Method

Wine Industry – Tartaric stabilization

chemicalstartarate

FiltratedWine

Cooling

EarthWastes = Ktart + Acid

Water + Acid

Treated Wine

Tart.K Electrodialysis


15 to 30 hL/h 120 to 240 hL/h

PROCESS IMPROVMENT : Reduction of water consumption ED combined to Reverse Osmosis (RO)

Performances of commercialized units : ED+RO 50% to 90 % water recovery Consumption : 3 to 5 L /hL wine including CIP (for a stab. rate of 12%

to 22 %)

ED

MF

RO

Waste

Water + Acid

Stabilized Wine


Optimized process for wine stabilization : ED + RO

Water consumption : 3 to 5% (3 à 5 L/hL of Wine)50% to 90 % water recovery – commercial unit

Electricity consumption : 0.4 kwh/ hL wine as maximum8 times lower than cold stabilization

Waste : RO retentate + CIP No wine losses

Perspectives : to reach “zero waste” with RO + crystallization. First results : 98% water recovery – Tartrate in crystal form –

valuable product


WINE INDUSTRY: TARTARIC STABILIZATION, PH ADJUSTMENT

OUR REFERENCES

CONCLUSION and PERSPECTIVES

The “Zero liquid Discharge” concept is a real good opportunity to introduce membrane technologies for agro-food industries

The key of success : To Know in detail the production line : quality of each

stream and volume (hard work) Combine properly each technologies (process approach) Complex process but possible to recover 100% chemicals

and water Discharge : minerals/organics coming from feed product Next step : give a value to this “natural” molecules


Thank you for yourattention!!

www.eurodia.com

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